1. Preparation
1. Preparation of tools and materials
Make sure to prepare suitable tools, such as wrenches, screwdrivers, pullers (if relevant parts need to be disassembled), etc. These tools should match the model and specifications of the pump to avoid damage to the pump body or other parts during disassembly and installation.
Prepare a new plunger. The model and specifications of the new plunger must be exactly the same as the original plunger. This includes parameters such as the plunger's diameter, length, material, and sealing structure. At the same time, ensure that the new plunger is of reliable quality and from a regular source to ensure its performance and service life.
Prepare seals and lubricants (if applicable). When replacing the plunger, it is usually necessary to replace related seals, such as plunger seals, O-rings, etc. at the same time. The material and size of the seal should match the pump body and plunger, and the type of lubricant should meet the requirements of the pump.
2. Shutdown and safety measures
Before replacing the plunger, the high-pressure pump must be stopped and the power supply (if it is an electric pump) or power source (if it is other drive methods) must be cut off. Hang a warning sign "Under maintenance, do not start" on the pump body to prevent accidental start-up causing casualties or equipment damage.
Release the pressure in the pump. The high-pressure water in the pump can be drained by opening the drain valve or other pressure relief device to ensure a safe operating environment.
2. Disassembly process
1. Marking and recording
Before removing the plunger, mark the relevant parts, pipes and connections. For example, mark the relative position of the plunger and the pump cylinder, the connection direction of the inlet and outlet pipes, etc. At the same time, record the order of disassembly and the placement of the parts so that they can be accurately restored during installation.
This helps to ensure that the various parts can be installed correctly during reassembly to avoid damage to the pump body or performance degradation caused by incorrect installation.
2. Disassemble related parts
Step by step, disassemble the parts related to the plunger in the order of marking and recording. This may include disassembling the connecting parts of the plunger, such as the connecting rod (if any), the crosshead (if any), etc. During the disassembly process, be careful to avoid unnecessary damage to other parts.
For some tight-fitting parts, such as the connection between the plunger and the pump cylinder, it may be necessary to use suitable tools for disassembly, such as pullers. However, when using tools, pay attention to the size and direction of the force applied to prevent damage to the parts.
3. Protect the pump cylinder and other parts
During the process of removing the plunger, pay attention to protecting the inner wall of the pump cylinder. The plunger has been running in the pump cylinder for a long time, and some wear products or impurities may be attached to the inner wall of the pump cylinder. When removing the plunger, avoid these substances from scratching the inner wall of the pump cylinder.
You can use a clean cloth or soft material to cover and protect the inner wall of the pump cylinder. At the same time, other disassembled parts should also be properly placed to prevent their surfaces from being scratched or stained with impurities.
III. Installation of new plungers
1. Cleaning and inspection
Before installing the new plunger, clean the new plunger to remove impurities such as oil, dust, etc. that may exist on the surface. At the same time, check whether the surface of the new plunger has defects such as scratches and sand holes to ensure that its surface is smooth and undamaged.
Clean and inspect the inside of the pump cylinder. Use a clean cloth or special cleaning tool to remove impurities, dirt and old sealing material residues from the inner wall of the pump cylinder. Check the inner wall of the pump cylinder for wear, corrosion, etc. If there is severe wear or corrosion, the pump cylinder may need to be repaired or replaced.
2. Install the seal
Install the new seal on the plunger. The seal should be installed in the correct order and method. For example, for some O-ring seals, make sure that they are installed in the correct position and cannot be twisted or overstretched.
Before installing the seal, you can apply a small amount of lubricating oil (if applicable) on the surface of the seal to facilitate installation and improve the sealing effect. But be careful not to use too much lubricating oil to avoid affecting the sealing performance.
3. Plunger installation
Install the new plunger into the pump cylinder slowly and steadily. During the installation process, make sure that the axis of the plunger and the pump cylinder are consistent to avoid damage to the plunger or the pump cylinder caused by forced installation. If you feel a lot of resistance during the installation process, do not force it. Check whether there is any foreign matter entering the pump cylinder or whether the plunger and the pump cylinder are properly matched.
Install the connecting parts related to the plunger, such as connecting rods, crossheads (if any), etc. according to the marked and recorded positions. When connecting these parts, make sure the connection is firm and tighten the bolts or nuts to the specified torque.
IV. Post-installation inspection and debugging
1. Overall inspection
After completing the replacement of the plunger and the installation of related parts, conduct a comprehensive inspection of the entire pump body. Check whether all connection parts are firm, whether the seal is good, and whether the pipes are connected correctly.
Check whether the oil level and oil quality of the lubricating oil (if applicable) are normal, and whether the electrical system (if it is an electric pump) is connected correctly and there is no risk of leakage.
2. Debugging operation
Carry out debugging operation. During the debugging process, start the high-pressure pump slowly first, and observe whether the running sound of the pump is normal and whether there is any abnormal vibration. At the same time, monitor whether the pressure and flow of the pump are within the normal range.
If abnormal conditions are found, such as unstable pressure, insufficient flow or abnormal noise, etc., stop the operation immediately, recheck the installation, find and solve the problem until the pump can operate normally and stably.